Hollow Fiber Structure of Aerogel and Method for Manufacturing the Hollow Fiber Structure

ABSTRACT

A fiber structure includes a fiber thread including a plurality of monofilaments juxtaposed to and combined with each other. Each of the monofilaments has a hollow shape. Each of the monofilaments is made of an aerogel and an artificial polymer. The aerogel and the artificial polymer are mixed together.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention relates to a fiber structure and, more particularly, to a hollow fiber structure of an aerogel and a method for manufacturing the hollow fiber structure.

2. Description of the Related Art

In the textile industry, the manufacturer always wishes to make a textile product that has a lighter weight, has a better warming effect and has an excellent thermal isolating feature, so as to provide a comfortable sensation to the consumer. The above features and purposes concerning the textile product are achieved by improving the spinning procedures and the textile material. However, the spinning procedures and the textile material encounter a bottleneck and cannot advance easily.

BRIEF SUMMARY OF THE INVENTION

The primary objective of the present invention is to provide a multi-filament fiber thread made of aerogel material, wherein each of the monofilaments of the multi-filament fiber thread has a hollow shape. Thus, the aerogel has multiple pores, and each of the monofilaments is hollow, so that the multi-filament fiber thread has a light weight and has a better isolation effect.

In accordance with the present invention, there is provided a fiber structure comprising a fiber thread including a plurality of monofilaments juxtaposed to and combined with each other. Each of the monofilaments has a hollow shape. Each of the monofilaments is made of an aerogel and an artificial polymer. The aerogel and the artificial polymer are mixed together.

Preferably, the aerogel of each of the monofilaments has a mass proportion of 0.5-10%.

Preferably, the artificial polymer of each of the monofilaments is made of PP, polyester, Nylon or acrylic.

Preferably, the fiber thread has a specification of 70D/72F.

In accordance with the present invention, there is further provided a method for manufacturing a fiber structure, comprising preparing a staple including an aerogel and an artificial polymer, hot melting the staple into a spinning solution and spinning the spinning solution by a plurality of annular injection holes to form a plurality of hollow monofilaments, and juxtaposing and combining the monofilaments into a fiber thread.

Preferably, the step of preparing a staple includes obtaining powder of the aerogel and particles of the artificial polymer, and evenly mixing the powder of the aerogel and the particles of the artificial polymer to form the staple.

Preferably, the step of preparing a staple includes adding powder of the aerogel and mixing the powder of the aerogel with the artificial polymer during polymerization of the artificial polymer to form the staple.

Preferably, the method further comprises working the fiber thread after the step of juxtaposing and combining the monofilaments.

According to the primary advantage of the present invention, each of the monofilaments contains the aerogel material which is porous and has a light weight. In addition, the aerogel material has an excellent thermal isolating feature, has greater strength and has a low density. Besides, each of the monofilaments has a hollow construction. Thus, the product made of the fiber thread 1 has a better isolating feature and has a lighter weight.

Further benefits and advantages of the present invention will become apparent after a careful reading of the detailed description with appropriate reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

FIG. 1 is a partially perspective view of a fiber structure in accordance with the preferred embodiment of the present invention.

FIG. 2 is a flow chart of a method for manufacturing the hollow fiber structure in accordance with the preferred embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Referring to the drawings and initially to FIG. 1, a hollow fiber structure in accordance with the preferred embodiment of the present invention comprises a fiber thread 1 including a plurality of monofilaments 11 juxtaposed to and combined with each other.

Each of the monofilaments 11 has a hollow (or tubular) shape. Each of the monofilaments 11 is made of an aerogel and an artificial polymer. The aerogel and the artificial polymer are mixed together. Each of the monofilaments 11 contains a plurality of aerogel particles 111 which are distributed evenly in each of the monofilaments 11. The aerogel of each of the monofilaments 11 has a mass proportion of 0.5-10%, and the artificial polymer of each of the monofilaments 11 has a mass proportion of 90-99.5%. The aerogel of each of the monofilaments 11 is made of silicon, carbon, nickel or the like, and the artificial polymer of each of the monofilaments 11 is made of PP, polyester, Nylon or acrylic.

In the preferred embodiment of the present invention, the fiber thread 1 has a specification of 70D/72F. The character “D” designates Denier (or Den) which means the weight (gram) of a fiber per nine thousand meters (9,000 m) of length. For example, 1D means the fiber has a weight of one gram (1 g) per 9,000 m. In addition, the character “F” designates the number of the monofilament of the fiber. Thus, the symbol of 70D/72F means the fiber thread 1 has a weight of 70 g per 9,000 m and has seventy two (72) monofilaments 11.

In the preferred embodiment of the present invention, the aerogel of each of the monofilaments 11 is porous and has multiple pores. For example, each of the aerogel particles 111 has multiple pores as shown in FIG. 1. Thus, each of the monofilaments 11 has a small density and has an excellent isolating effect. In addition, each of the monofilaments 11 is hollow so that the fiber thread 1 has a lighter weight.

Referring to FIG. 2 with reference to FIG. 1, a method for manufacturing the hollow fiber structure comprises a first step 2 of preparing a staple, a second step 3 of forming the monofilaments 11, a third step 4 of forming the fiber thread 1, and a fourth step 5 of working the fiber thread 1.

The first step 2 includes preparing a staple including an aerogel and an artificial polymer which are mixed together, with the aerogel having a mass proportion of 0.5-10%, and with the artificial polymer being made of PP, polyester, Nylon or acrylic.

The second step 3 includes hot melting the staple into a spinning solution and spinning the spinning solution into a plurality of hollow monofilaments 11 each of which contains a plurality of aerogel particles 111, with the aerogel particles 111 being distributed evenly in each of the monofilaments 11.

The third step 4 includes juxtaposing and combining the monofilaments 11 into a fiber thread 1.

The fourth step 5 includes performing a working process on the fiber thread 1.

In the preferred embodiment of the present invention, the first step 2 includes directly evenly mixing powder of the aerogel and particles of the artificial polymer to form the staple.

Alternatively, the first step 2 includes adding powder of the aerogel and mixing the powder of the aerogel with the artificial polymer during polymerization of the artificial polymer to form the staple with a mixture of the aerogel and the artificial polymer.

In the preferred embodiment of the present invention, the second step 3 includes spinning the spinning solution into the hollow monofilaments 11 by fuse spinning, wet spinning or dry spinning For example, when the fuse spinning is performed, the staple is thrown into a hopper and then enters a screw press so that the staple is heated in the screw press and melted to form the spinning solution. Then, the spinning solution is pressed by the screw press and delivered into a spinning box. Then, a counting pump in the spinning box conveys the spinning solution to a nozzle (or an injection board). Then, the spinning solution is extruded through multiple injection holes of the nozzle to form the monofilaments 11. Then, the monofilaments 11 are cooled. At this time, each of the injection holes of the nozzle has an annular shape, so that each of the monofilaments 11 has a hollow shape.

In the preferred embodiment of the present invention, the third step 4 includes guiding the monofilaments 11 by a guiding device and juxtaposing and combining the monofilaments 11 to form the fiber thread 1. Preferably, the guiding device is a guide disk.

In the preferred embodiment of the present invention, the fourth step 5 includes working the fiber thread 1 by drawing, heating, curling or twisting, to enhance the elasticity, strength and suspension of the fiber thread 1. The working procedures of the fiber thread 1 are traditional and will not be further described in detail.

Accordingly, the aerogel is porous and has low density, and each of the monofilaments 11 has a hollow shape, so that the product made of the fiber thread 1 has a better isolating feature and has a lighter weight.

Although the invention has been explained in relation to its preferred embodiment(s) as mentioned above, it is to be understood that many other possible modifications and variations can be made without departing from the scope of the present invention. It is, therefore, contemplated that the appended claim or claims will cover such modifications and variations that fall within the scope of the invention. 

1. A fiber structure comprising: a fiber thread including a plurality of monofilaments juxtaposed to and combined with each other; wherein: each of the monofilaments has a hollow shape; each of the monofilaments is made of an aerogel and an artificial polymer; and the aerogel and the artificial polymer are mixed together.
 2. The fiber structure of claim 1, wherein the aerogel of each of the monofilaments has a mass proportion of 0.5-10%.
 3. The fiber structure of claim 1, wherein the artificial polymer of each of the monofilaments is made of PP, polyester, Nylon or acrylic.
 4. The fiber structure of claim 1, wherein the fiber thread has a specification of 70D/72F.
 5. A method for manufacturing a fiber structure, comprising: preparing a staple including an aerogel and an artificial polymer, hot melting the staple into a spinning solution and spinning the spinning solution by a plurality of annular injection holes to form a plurality of hollow monofilaments, and juxtaposing and combining the monofilaments into a fiber thread.
 6. The method of claim 5, wherein the step of preparing a staple includes obtaining powder of the aerogel and particles of the artificial polymer, and evenly mixing the powder of the aerogel and the particles of the artificial polymer to form the staple.
 7. The method of claim 5, wherein the step of preparing a staple includes adding powder of the aerogel and mixing the powder of the aerogel with the artificial polymer during polymerization of the artificial polymer to form the staple.
 8. The method of claim 5, further comprising: working the fiber thread after the step of juxtaposing and combining the monofilaments. 